Volkswagen Golf 5 2004- VW Rabbit GTI 2006

VAS 5051 / 5052                                                  Page 1 / 3



Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->                         97 - 1




VAS 5051 / 5052
General information

On Board Diagnostic (OBD) program functions must be
carried out using either the Vehicle Diagnostic, Testing and
Information System VAS 5051 or Vehicle Diagnostic and
Service System VAS 5052 .

Specific service, On Board Diagnostic (OBD) and
component / function troubleshooting procedures are
available via tester operating modes "Guided Fault
Finding" or "Guided Functions" .

Additional information:

  Self Study Program - Course Number 811203 "VAS
5052 Design and Function"

  VAS 5051 / VAS 5052 Operating instructions

  VAS 5051 / VAS 5052 Operating mode
"Administration" .

- Connect Vehicle Diagnostic, Testing and Information
System VAS 5051/5052       97-1, Vehicle Diagnostic,
Testing and Information System VAS 5051 / 5052 ,
connecting .

Scan Tool (ST) and Test Equipment, Safety Precautions

Warning!

         „   Due to weight, size and need for manual
             operation of test instruments while vehicle is
             driven on public roads, instrument must be used
             only with a Driver operating the vehicle and an
             Instrument Operator operating the test
             equipment.


         „   Do not use Instrument with Driver only. Always
             use two persons to conduct test.


         „   Do not place Instrument on lap of Driver or front
             seat passenger because emergency stop may
             dislodge Instrument and cause airbag
             deployment with risk of injury to Instrument
             Operator.
VAS 5051 / 5052                                                  Page 2 / 3




          „   Place Instrument in rear seating area and secure
              by available safety belt.


          „   Instrument Operator must be seated in the other
              rear seating position, after sliding front
              passenger seat and moving the seat back as far
              forward as possible. Do not activate the seat
              back release lever.


          „   Instrument Operator must wear safety belt.


Vehicle Diagnostic, Testing and Information System VAS
5051 / 5052 , connecting

Special tools, testers and auxiliary items required




   „   Vehicle Diagnostic, Testing and Information System
       VAS 5051/5052 (VAS 5051 A version shown as
       example only)




   „   Diagnostic cable VAS 5051/6A (5 m)


   „   Diagnostic cable VAS 5051/5A (3 m)
VAS 5051 / 5052                                                Page 3 / 3




Note:

   „   Only the diagnostic cables listed above are to be
       used. Cables are equipped with CAN-wires that
       permit diagnosis of CAN-Bus systems.


Connecting:

- Engage parking brake.

- For vehicles with automatic or DSG transmission, bring
selector lever into position "P" or "N" .

- For vehicles with manual transmission, bring shift lever
into neutral position.

- Switch off all electrical consumers.




- With ignition switched off, connect Vehicle Diagnostic,
Testing and Information System VAS 5051/5052 with
diagnostic cable VAS 5051/6A to Data Link Connector
(DLC) located under left lower portion of instrument panel -
arrow - .

- Switch ignition on.

- Select operating mode "Guided Fault Finding" , "Vehicle
Self Diagnosis" or "Guided Functions"

The DTC memory of all control modules will be checked:

- Enter information as prompted. Where required, press ">"
to confirm

- Follow tester prompts
Fuse Panel                                                        Page 1 / 2



                                                                       97 - 2




Fuse Panel
Fuse panel, removing and installing

Special tools, testers and auxiliary items required




    „   Trim removal wedge VAS 3409


Caution!

          „   When disconnecting and reconnecting battery
              terminals, observe all applicable Notes and
              torque specifications, as well as instructions on
              performing OBD program and electrical system
              function checks as specified in this Repair
              Manual 27-4, Battery, disconnecting and
              connecting .


          „   When removing switches, trim, covers or
              displays, prevent damage to visible areas of the
              interior by always applying appropriate tape to
              area surrounding the component, and the tools
              being used (screwdrivers, wedges etc.).


Removing:

- Disconnect battery     27-4, Battery, disconnecting and
connecting .

- Remove drivers storage compartment where applicable



    Repair Manual, Body Interior, Repair Group 68,

.
Fuse Panel                                                    Page 2 / 2




- Remove left instrument panel side cover - 1 - by
inserting trim removal wedge VAS 3409 or a screwdriver
into recess - 2 - and pry off cover - 1 - in direction of -
arrow - .




- Remove fuse assignment card - 1 - from fuse panel - 2 -
.

- Remove screws - arrows - and guide fuse panel - 1 -
outward as far as cable lengths permit.

Installing:

Install in reverse order of removal.
Relay Panels                                                Page 1 / 4



                                                                 97 - 3




Relay Panels
Relay/fuse panel under left instrument panel, removing
and installing

Caution!

When disconnecting and reconnecting battery
terminals, observe all applicable Notes and torque
specifications as well as instructions on performing
OBD program and electrical system function checks as
specified in this Repair Manual 27-4, Battery,
disconnecting and connecting .

Removing:

- Disconnect battery     27-4, Battery, disconnecting and
connecting .

- Remove drivers compartment where applicable



    Repair Manual, Body Interior, Repair Group 68,

.




- Remove relays - arrows - from relay carrier.

Note:

    „   The number of relays is dependent on vehicle
        equipment.
Relay Panels                                                   Page 2 / 4




- Release retaining tab in direction of - arrow - then press
relay holders - 1 - out of relay panel.




- Release retainer - 1 - for relay panel in direction of -
arrow - and remove relay panel.

Installing:

Install in reverse order of removal, noting the following:

- First clip connector into relay carrier.




- Place relay carrier - 2 - into guide - 1 - and then engage
relay carrier.

Relay panel integrated with Vehicle Electrical System
Relay Panels                                                     Page 3 / 4




Control Module J519 , removing and installing

Note:

    „   The relay panel integrated with Vehicle Electrical
        System Control Module J519 is permanently
        attached and cannot be serviced separately.


    „   If Vehicle Electrical System Control Module J519 is
        to be replaced, the work procedure to read out the
        coding stored in the module must always be
        performed 97-5, Vehicle Electrical System Control
        Module J519 , coding .


Removing:

Caution!

           „   Switch off all electrical consumers.


           „   Switch ignition off and remove ignition key.


- Remove drivers footwell cover



    Repair Manual, Body Interior, Repair Group 68,

.

- Remove drivers storage compartment where applicable



    Repair Manual, Body Interior, Repair Group 68,

.




- Disengage electrical connection lock - 1 - in direction of -
Relay Panels                                                  Page 4 / 4




arrow A - .

- Disengage electrical connection lock - 2 - at Vehicle
Electrical System Control Module J519 in direction of -
arrow B - .

Note:

   „   Harness connectors of Vehicle Electrical System
       Control Module J519 and of relay carrier at vehicle
       electrical system control module, at left instrument
       panel, can only be disconnected if lock is brought
       into position "OPEN" beforehand.


- Disconnect all electrical connections to relay panel.

Note:

   „   The number of electrical connections depends on
       vehicle equipment.


- Unclip Vehicle Electrical System Control Module J519
with relay panel from latches - arrows C - .

- Pull Vehicle Electrical System Control Module J519 with
relay panel downward and out of bracket in opposite
direction of travel.

Installing:

Install in reverse order of removal, noting the following:

Note:

   „   Electrical connection locks can only be brought into
       position " CLOSE" when all connections are
       connected "correctly" .
Electronics Boxes (E-Boxes)                                    Page 1 / 6



                                                                    97 - 4




Electronics Boxes (E-Boxes)
E-Box in engine compartment - left, removing and
installing

Note:

   „   Depending on equipment, two different E-boxes are
       used: either "E-Box High" or "E-Box Low" . The
       following illustrations show "High" version. Removal
       and installation of "Low" version is the same.


Caution!

When disconnecting and reconnecting battery
terminals, observe all applicable Notes and torque
specifications as well as instructions on performing
OBD program and electrical system function checks as
specified in this Repair Manual 27-4, Battery,
disconnecting and connecting .

Removing:

- Disconnect battery     27-4, Battery, disconnecting and
connecting .




- Slide retainers - 1 - in direction of - arrow - and remove
E-box cover - 2 - upward.

Note:

   „   Mark location of cables connected to E-box.
Electronics Boxes (E-Boxes)                                Page 2 / 6




- Remove nuts - 1 - .

- Open - arrows - covers - 2 - for wire guides at E-box.

- Remove wires from connecting pins.

- Unclip wires from wire guides.




- Remove central screw - arrow - for E-box - 1 - .

Note:

   „   Removing the central screw - arrow - presses off
       the E-box - 1 - upward from E-box bracket.


- Remove E-box - 1 - upward from E-box bracket.

Note:
Electronics Boxes (E-Boxes)                               Page 3 / 6




   „   In order to remove flat terminal housing - 1 - ,
       battery and battery console must be removed.


- If necessary, remove air filter housing.

- Remove battery      27-5, Battery, removing and
installing .




- Remove screws - arrows - for battery console - 1 - .

- Remove battery console - 1 - from vehicle.
Electronics Boxes (E-Boxes)                                   Page 4 / 6




- Press straps on E-box bracket apart from each other -
arrows B - and slide flat terminal housing - 1 - sideways -
arrow A - from E-box bracket.

only vehicles with "High" E-box version:

- Press straps on E-box bracket apart from each other -
arrows C - and slide flat terminal housing - 2 - toward
front - arrow D - from E-box bracket.

all vehicles:




- Remove nuts - arrows - of E-box bracket - 1 - .

Note:

   „   Depending on vehicle equipment, an auxiliary relay
       panel may be installed.
Electronics Boxes (E-Boxes)                                     Page 5 / 6




- Pull E-box bracket - 1 - upwards from studs as far as
cable lengths permit.

- Unclip auxiliary relay carrier - 1 - sideways from E-box
bracket - 2 - .

- Remove E-box bracket - 2 - from vehicle.

Installing:

Install in reverse order of removal, noting the following:




- Reconnect wires - 1 - to E-box in allocation marked
during removal Electrical Wiring Diagrams,
Troubleshooting and Component Locations binder .

- Tighten all fasteners according to values in table    97-6,
E-Box in engine compartment, tightening torques .
Electronics Boxes (E-Boxes)                                   Page 6 / 6




- Place cover - 2 - onto E-box and slide retainers - 1 - in
direction of - arrow - until engaged.

Note:

   „   Always confirm E-Box cover - 2 - is correctly
       engaged.
Control Modules                                              Page 1 / 14



                                                                   97 - 5




Control Modules
Vehicle Electrical System Control Module J519

Note:

   „   The relay panel integrated with Vehicle Electrical
       System Control Module J519 is permanently
       attached and cannot be serviced separately.


   „   If Vehicle Electrical System Control Module J519 is
       to be replaced, the work procedure to read out the
       coding stored in the module must always be
       performed 97-5, Vehicle Electrical System Control
       Module J519 , coding .


General information:

Vehicle Electrical System Control Module J519 controls
the function of the following components/systems:

          „   Electric load management


          „   Exterior light control


          „   Turn signal control


          „   Wipers, rear window


          „   Heated rear window


          „   Interior light control


          „   Shift-/selector gate illumination


          „   Terminal control


          „   Dimming, instrument illumination


          „   Fuel Pump (FP) supply
Control Modules                                                   Page 2 / 14




          „   Pre-energizing of generator


          „   Horn


The following functions can be adapted:

          „   Erase learned values and set standard adaptation
              values


          „   Adjust Coming Home Time (equipment dependent)


          „   Adjust Leaving Home Time (equipment dependent)


          „   Set rear window heater "on time"


          „   Switch footwell lights on and off


          „   Switch highway signaling on and off


          „   Set load management


          „   Set headlamp cleaning system "on time"      97-5,
              Headlamp washer system, adaptation


Note:

   „   Adaptations listed above are dependent on vehicle
       equipment level and market version.


   „   "Highway signaling" , "comfort-flashing" , or "tap
       signaling" means that turn signals are activated
       multiple times (1-5 times) when turn signal lever is
       tapped once (signal cycles).


   „   Additional information:


  Owners Manual

  Self Study Program - Course Number 892503 "VW 2006
GTI Introduction"

  Wiring Diagrams and Component Locations
Control Modules                                                 Page 3 / 14




On Board Diagnostic (OBD), functions:

Vehicle Electrical System Control Module J519 is
controlled by an internal microprocessor with On Board
Diagnostic (OBD) capability. If malfunctions occur in
monitored components, Diagnostic Trouble Codes (DTC)
will be stored in memory.

Troubleshoot Vehicle Electrical System Control Module
J519 malfunctions by performing OBD program using
Vehicle Diagnosis, Testing and Information System VAS
5051/5052 in operating mode "Guided Fault Finding" .

Vehicle Electrical System Control Module J519 , removing and
installing

Note:

   „   If Vehicle Electrical System Control Module J519 is
       to be replaced, the work procedure to read out the
       coding stored in the module must always be
       performed 97-5, Vehicle Electrical System Control
       Module J519 , coding .


Removing:

Remove relay panel integrated with Vehicle Electrical
System Control Module J519        97-3, Relay panel
integrated with Vehicle Electrical System Control Module
J519 , removing and installing

Installing:

Install relay panel integrated with Vehicle Electrical System
Control Module J519        97-3, Relay panel integrated with
Vehicle Electrical System Control Module J519 , removing
and installing

Vehicle Electrical System Control Module J519 , checking with
Output Diagnostic Test Mode (DTM)

The function of many electrical components can be
checked via output Diagnostic Test Mode (DTM) of Vehicle
Electrical System Control Module J519 .

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052

- Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:
Control Modules                                             Page 4 / 14




- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Electrical system int/ext (Repair Group 01; 27;
90-97)"

- Select "01 - Self-diagnosis"

- Select "Vehicle Electrical System Control Module"

- Select "Vehicle Electrical System Control Module
functions"

- Select "J519 - output DTM, sequential (Repair Group
97)"

- Press ">" to confirm.

- Select "1 - Output Diagnostic Test Mode (DTM) for an
individual component"

- Search and select appropriate light or switch component
from menu, or

- Select "2 - Output Diagnostic Test Mode (DTM) for all
actuators"

- Follow tester prompts

Vehicle Electrical System Control Module J519 , coding

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052 .

- Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:

- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Electrical system int/ext (Repair Group 01; 27;
90-97)"

- Select "01 - Self-diagnosis"

- Select "Vehicle Electrical System Control Module"

- Select "Vehicle Electrical System Control Module
functions"
Control Modules                                               Page 5 / 14




- Select "Coding"

- Press ">" to confirm.

- Follow tester prompts

Headlamp washer system, adaptation

The "active time" of headlamp washer system can be
adjusted variably between 0 seconds and 12.75 seconds.

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052

- Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:

- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Electrical system int/ext (Repair Group 01; 27;
90-97)"

- Select "01 - Self-diagnosis"

- Select "Vehicle Electrical System Control Module"

- Select "Vehicle Electrical System Control Module
functions"

- Select "Adapting headlamp washer system"

- Press ">" to confirm.

- Follow tester prompts

Data Bus On Board Diagnostic Interface J533

General information:

The Data Bus On Board Diagnostic Interface J533
"Gateway" is no longer integrated with the instrument
cluster. It is now a separate control module.

"J533" performs the following functions:

         „   Performs data exchange between CAN-Bus systems
             "CAN-Bus powertrain" , "CAN-Bus comfort" and
             "CAN-Bus Infotainment"
Control Modules                                                   Page 6 / 14




          „   Transfers diagnostic data of CAN-Bus systems onto
              K-wire and vice-versa, allowing data from Vehicle
              Diagnosis, Testing and Information System VAS
              5051/5052 to be utilized


Note:

   „   If Data Bus On Board Diagnostic Interface J533 is to
       be removed, the work procedure to read out the
       coding stored in the module must always be
       performed 97-5, Data Bus On Board Diagnostic
       Interface J533 , replacing .


   „   Additional information:


  Owners Manual

  Self Study Program - Course Number 892503 "VW 2006
GTI Introduction"

  Wiring Diagrams and Component Locations

On Board Diagnostic (OBD), functions:

Data Bus On Board Diagnostic Interface J533 is controlled
by an internal microprocessor with On Board Diagnostic
(OBD) capability. If malfunctions occur in monitored
components, Diagnostic Trouble Codes (DTC) will be
stored in memory.

Troubleshoot Data Bus On Board Diagnostic Interface
J533 malfunctions by performing OBD program using
Vehicle Diagnosis, Testing and Information System VAS
5051/5052 in operating mode "Guided Fault Finding" .

Data Bus On Board Diagnostic Interface J533 , replacing

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052 .

- Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:

- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Electrical system int/ext (Repair Group 01; 27;
Control Modules                                               Page 7 / 14




90-97)"

- Select "01 - Self-diagnosis"

- Select "Diagnostic interface for databus"

- Select "Functions"

- Select "Diagnostic interface for databus, replacing"

- Press ">" to confirm.

- Follow tester prompts

Data Bus On Board Diagnostic Interface J533 , removing and
installing

Note:

    „   Before removing Data Bus On Board Diagnostic
        Interface J533 , the work procedure to read out the
        coding stored in the module must always be
        performed 97-5, Data Bus On Board Diagnostic
        Interface J533 , replacing .


Removing:

Caution!

           „   Switch off all electrical consumers.


           „   Switch ignition off and remove ignition key.


- Remove drivers footwell cover



    Repair Manual, Body Interior, Repair Group 68,

.
Control Modules                                            Page 8 / 14




- Disengage electrical connection lock - 1 - and
disconnect from Data Bus On Board Diagnostic Interface
J533 - 2 - .

- Press mounting pins - 3 - together - arrows - and from
holes.

Installing:

Install in reverse order of removal.

Comfort System Central Control Module J393

General information:

Comfort System Central Control Module J393 performs the
following functions:

          „   Sunroof control (issues enabling)


          „   Window regulator control (issues enabling)


          „   Central locking system control


          „   Anti-theft warning system control


          „   Radio receiver


          „   Rear lid closing


          „   Comfort operation


Some of the functions listed above can be adapted  97-5,
Comfort System Central Control Module J393 , adapting .

Note:

   „   Additional information:


  Owners Manual

  Self Study Program - Course Number 892503 "VW 2006
GTI Introduction"

  Wiring Diagrams and Component Locations

On Board Diagnostic (OBD), functions:
Control Modules                                             Page 9 / 14




Comfort System Central Control Module J393 is controlled
by an internal microprocessor with On Board Diagnostic
(OBD) capability. If malfunctions occur in monitored
components, Diagnostic Trouble Codes (DTC) will be
stored in memory.

Troubleshoot Comfort System Central Control Module
J393 malfunctions by performing OBD program using
Vehicle Diagnosis, Testing and Information System VAS
5051/5052 in operating mode "Guided Fault Finding" .

Comfort System Central Control Module J393 , removing and
installing

Removing:

Caution!

         „   Switch off all electrical consumers.


         „   Switch ignition off and remove ignition key.


- Remove glove compartment



   Repair Manual, Body Interior, Repair Group 68, storage
compartments, covers and panels; removing and installing
glove compartment

.




- Pull retaining tab - 1 - of bracket of Comfort System
Central Control Module J393 in direction of - arrow - and
slide Comfort System Central Control Module J393 until
recesses - 2 - stand over recesses - 3 - .

Note:
Control Modules                                            Page 10 / 14




   „   Electrical connections can only be disengaged and
       disconnected when recesses - arrows - are lined
       up.


- Release and disconnect electrical connections from
Comfort System Central Control Module J393 .

Note:

   „   The number of electrical connections depends on
       vehicle equipment level and market version.




- Remove nuts - arrows - .

- Remove bracket with Comfort System Central Control
Module J393 .
Control Modules                                               Page 11 / 14




- Pull retaining tab - 1 - in direction of - arrow B - and
slide module - 2 - from bracket in direction of - arrow A -
.

Installing:

Install in reverse order of removal, noting the following:

Note:

   „   After installing a new Comfort System Central
       Control Module, it must be coded 97-5, Comfort
       System Central Control Module J393 , coding .




   „   Electrical connections can only be disengaged and
       disconnected when recesses - arrows - are lined
       up.


Comfort System Central Control Module J393 , coding

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052 .

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052 .

- Select operating mode "Guided Fault Finding"
Control Modules                                                      Page 12 / 14




- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:

- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Repair work int/ext (Repair Group 01; from 55 to
77)"

- Select "01 - Self-diagnosis"

- Select "46 - Central module comfort system"

- Select "Functions"

- Select "Coding"

- Press ">" to confirm.

- Follow tester prompts

Comfort System Central Control Module J393 , adapting

The following functions can be adapted (depending on
vehicle equipment):

         „   Activating and deactivating "single door opening"


         „   Activating and deactivating "automatic locking at >15
             Km/h"


         „   Activating and deactivating "automatic unlocking
             when removing ignition key"


         „   Activating and deactivating "country setting for
             intelligent alarm horn"


         „   Activating and deactivating "battery monitoring
             (sounder)"


         „   Activating and deactivating "comfort operation via
             radio-frequency remote control"


         „   Activating and deactivating "anti-theft warning
             system - alarm delay when opening driver door"
Control Modules                                               Page 13 / 14




- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052 .

- Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:

- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Repair work int/ext (Repair Group 01; from 55 to
77)"

- Select "01 - Self-diagnosis"

- Select "46 - Central module comfort system"

- Select "Functions"

- Select "Adaptation"

- Press ">" to confirm.

- Follow tester prompts

Comfort System Central Control Module J393 Anti-theft alarm
system, checking alarm sources

- Connect Vehicle Diagnosis, Testing and Information
System VAS 5051/5052      97-1, VAS 5051 / 5052 .

- Select operating mode "Guided Fault Finding"

- Enter information as prompted and press ">" to confirm.

After the DTC memory of all control modules has been
checked:

- Use "Go to" button to select "Function / Component
Selection"

- Select "Body (Repair Group 01; 27; 50-97)"

- Select "Repair work int/ext (Repair Group 01; from 55 to
77)"

- Select "01 - Self-diagnosis"

- Select "46 - Central module comfort system"

- Select "Functions"
Control Modules                                         Page 14 / 14




- Select "Comfort System Central Control Module J393,
checking alarm sources of anti-theft alarm system"

- Press ">" to confirm.

- Follow tester prompts

Garage Door Opener Control Module J530

Garage Door Opener Control Module J530 , removing and
installing

- Garage Door Opener Control Module J530 , removing
and installing 96-7, Garage Door Opener Control Head
E284 , removing and installing

Checking Garage Door Opener Control Module J530

Information not available at time of publication
Wiring, tightening torques                                                Page 1 / 1



                                                                               97 - 6




Wiring, tightening torques




E-Box in engine compartment, tightening torques

Fastener / location                                  Tightening torques
E-Box / nuts - 1 -                      M5 (8 mm)    4 Nm
E-Box / nuts - 1 -                      M6 (10 mm)   6 Nm
E-box central screw on bracket                       9 Nm
Wiring Harness and Connectors, repairing                         Page 1 / 45



                                                                       97 - 7




Wiring Harness and Connectors, repairing
Safety measures

Caution!

Before beginning repairs on the electrical system:

         „   Where applicable, obtain the anti-theft radio
             security code .


         „   Switch off all electrical consumers.


         „   Switch ignition off and remove ignition key.


         „   Disconnect negative ( - ) battery terminal.


         „   When disconnecting and reconnecting battery
             terminals, observe all applicable Notes and
             torque specifications, as well as instructions on
             performing OBD program and electrical system
             function checks as specified in this Repair
             Manual 27-4, Battery, disconnecting and
             connecting . Not adhering to proper
             disconnection sequence will result in the
             deactivation of Main Battery Switch -E74- and
             subsequent damage to electrical system
             components.


Caution!

         „   Airbag and safety belt tensioner harness and
             connector repairs must only be performed using
             VAS 1978 Wiring Harness Repair Kit VAS 1978
             Instruction Manual .


         „   Airbag and safety belt tensioner harness and
             connector repairs must only be performed using
             applicable wires, connectors and terminals
             Parts Catalog .


Wiring harness repair kit

Wiring Harness Repair Kit VAS1978
Wiring Harness and Connectors, repairing                        Page 2 / 45




Wiring Harness Repair Kit VAS1978 makes optimal repair
quality possible within vehicle electronics. Using the tools,
repairs affecting harness connectors and breaks in wiring
can be performed. For this purpose, complete repair wires
with terminals already crimped on are used and can be
connected to vehicle-specific wiring harness by the use of
crimp connections. A pair of crimping pliers with three
different crimp slots and a hot air gun for shrinking the
crimp connections provide trouble-free electrical
connection.

Note:

   „   For additional information:


  Users instructions of Wiring Harness Repair Kit
VAS1978

Upgrade kit VAS 1978/50 (where applicable)




Upgrade kit VAS 1978/50 is required to bring the "old"
Wiring Harness Repair Kit VAS1978 up to the new
standard of Wiring Harness Repair Set VAS1978A . The
upgrade kit contains 4 assembly- and 10 release tools as
well as new crimp pliers for crimp connections with
exchangeable heads for 0.35 mm - 2.5 mm VAS 1978/1-
1 , 4.0 mm - 6.0 mm VAS 1978/2A and changeable head
for JPT VAS 1978/9-1 . Furthermore it contains new
Wiring Harness and Connectors, repairing                      Page 3 / 45




stickers, a new set of user instructions, crimp connections
for 0.35mm 2 -wire cross sections and a roll of black felt
adhesive tape.

Wiring Harness Repair Set VAS1978A




The new Wiring Harness Repair Set VAS1978A makes
optimal repair quality possible within vehicle electronics.
Using the new pliers, repairs affecting harness connectors
and breaks in wiring can be performed. For this purpose,
complete repair wires with terminals already crimped on
are used and can be connected to vehicle-specific wiring
harness by the use of the four different types of crimp
connections. A pair of new crimping pliers with
exchangeable heads and a hot air gun for shrinking the
crimp connections provide trouble-free electrical
connection.

Note:

   „   For additional information:


  Users instructions of Wiring Harness Repair Set
VAS1978A

Release Tool Set VAS1978/35




The Release Tool Set VAS1978/35 is used to release the
Wiring Harness and Connectors, repairing                                            Page 4 / 45




various primary and secondary locking mechanisms on
VW-group vehicles. The set consists of 26 different tools
which can be used to professionally release or assemble
e.g. round connector systems, flat terminals with one or
two locks as well as single wire seals.

The application of the correct release tools to the
respective locks can be found in the table in users
instructions for Release Tool Set VAS1978/35 .

Tool descriptions

Crimp pliers with insert




The Crimping Pliers Without Insert VAS1978/1 , with Insert
For Crimping Pliers VAS1978/2 , is a component of Wiring
Harness Repair Kit VAS1978 and is used to crimp the
crimp connection during wiring harness repair.

Crimp connection color                 Crimp slot color       Wire cross-section
yellow                                 yellow                 0.35 mm 2
red                                    red                    0.5 mm 2 - 1.0 mm 2
blue                                   blue                   1.5 mm 2 - 2.5 mm 2
yellow                                 yellow                 4.0 mm 2 - 6.0 mm 2

Note:

   „   Crimping pliers (base tool) VAS 1978/1-2 in
       conjunction with exchangeable heads VAS 1978/1-
       1 or VAS 1978/2A can also be used to crimp the
       connections as an alternative 97-7, Crimp pliers
       VAS 1978/1A (where applicable) .


   „   Always be sure to use the correct crimp slot for the
       crimp connection used.


   „   Do not crimp wire insulation.
Wiring Harness and Connectors, repairing                      Page 5 / 45




Release tools for terminals




Various release tools are used to remove the different
terminals from terminal housings without damage.

A selection of release tools are a component of Wiring
Harness Repair Kit VAS1978 and of Wiring Harness
Repair Set VAS1978A . Release Tool Set VAS1978/35
contains the entire set of release tools 97-7, Release
Tool Set VAS1978/35 .

Warning!

Some tools are supplied with a tool safety clip, which
is slid over the tool points after using the tool, in order
to protect other workers from injuries and tool points
from damage.

Releasing and disassembling terminal housings    97-7,
Terminal housings, releasing and disassembling .

Assembly tools for single wire seals




Assembly tools allow single wire seals to be slid into
terminal housing up to stop without damage, this achieves
a complete seal between single wire and terminal housing.
Wiring Harness and Connectors, repairing                        Page 6 / 45




Four assembly tools for single wire seals are components
of Wiring Harness Repair Kit VAS1978 and of Wiring
Harness Repair Set VAS1978A .

Assembly of single wire seals      97-7, Assembly of single
wire seals .

Wire Stripper VAS1978/3




Wire Stripper VAS1978/3 is used for professional stripping
and cutting of wires.

Wire Stripper VAS1978/3 is a component of Wiring
Harness Repair Kit VAS1978 and of Wiring Harness
Repair Set VAS1978A .

Wire stripper has an adjustable stop in its pliers-jaws which
can be set to the desired length of wire insulation to be
removed.

Stripping:

- Set the slideable stop in pliers-jaws to the desired length
dimension to be stripped.




- Insert wire end from front up to stop into jaws of pliers
and squeeze the pliers completely.

- Open pliers again and remove the stripped wire end.
Wiring Harness and Connectors, repairing                      Page 7 / 45




- If necessary, cut wires using side-cutter function on the
top of the wire stripper.




Hot Air Gun VAS1978/14

Caution!

When heat-shrinking crimp connections, do not
damage any other wiring, plastic parts or insulating
material with the hot air gun nozzle.

Always observe operating instructions of heat gun.

Hot Air Gun VAS1978/14 is used in conjunction with
Shrink Tip For Hot Air Gun VAS 1978/15 to heat-shrink the
crimp connections. After crimping, heat-shrink crimp
connections using hot air gun to prevent moisture
penetration.



Hot Air Gun VAS1978/14 is a component of Wiring
Harness Repair Kit VAS1978 and of Wiring Harness
Repair Set VAS1978A .

Heat-shrinking crimp connections using Hot Air Gun
VAS1978/14      97-7, Wire break with single repair point ,
or 97-7, Wire break with dual repair point .

Crimp pliers VAS 1978/1A (where applicable)
Wiring Harness and Connectors, repairing                       Page 8 / 45




Crimp pliers VAS 1978/1A or crimp pliers (basic tool) VAS
1978/1-2 together with exchangeable head 0.35 - 2.5mm/2
VAS 1978/1-1 or exchangeable head 4.0 - 6.0mm/2 VAS
1978/2A from wiring harness repair kit is used to
compress the crimp connections.

Compressing crimp connections using crimp pliers VAS
1978/1A   97-7, Wire break with dual repair point .

The following exchangeable heads can be obtained for
crimp pliers (basic tool) VAS 1978/1-2 :

         „   Exchangeable head 0.35 mm 2 - 2.5 mm 2 VAS
             1978/1-1


         „   Exchangeable head 4.0 mm 2 - 6.0 mm 2 VAS
             1978/2A


         „   Exchangeable head for JPT-terminal VAS 1978/9-1


In conjunction with exchangeable head for JPT-terminal
VAS 1978/9-1 , crimp pliers is used to crimp on terminals
on to individual wires when repairing wiring cross-sections
up to 0.35 mm 2 97-7, Repairing wires with a cross-
section up to 0.35 mm 2 .

Use crimp pliers in conjunction with exchangeable head for
JPT-terminal VAS 1978/9-1 to crimp terminals on to
individual wires when repairing wiring cross-sections up to
0.35 mm 2 97-7, Repairing wires with a cross-section up
to 0.35 mm 2 .

Changing exchangeable head:

- Open crimp pliers completely.
Wiring Harness and Connectors, repairing                     Page 9 / 45




- Disengage both locking pins - arrows - from crimp pliers
basic tool.




- Insert the required exchangeable head in crimp pliers
basic tool from above - arrow - .




- Lock exchangeable head into crimp pliers basic tool by
pressing in the pins - arrows - .

Electrical system, general repair measures

Caution!

When disconnecting and connecting battery, the
procedure must be followed as described in the Repair
Manual 27-4, Battery, disconnecting and
Wiring Harness and Connectors, repairing                             Page 10 / 45




connecting .

Always refer to and heed CAUTION! and WARNING!
texts associated with repair and/or removal and
installation information in the Repair Manual.

Only the yellow repair cables and insulation tape
supplied with VAS 1978 are to be used for
wiring/connector repairs. The use of yellow repair
wires and yellow insulation tape identifies that a repair
has taken place VAS 1978 Instruction Manual .

Before beginning wiring and connector repairs,
determine and rectify the cause of damage, Eg.:
pinched between metal parts, malfunctioning electrical
consumers, corrosion due to water ingress etc.

Avoid loosening or removing any individual ground
connections (potential for corrosion).

When repairs are completed, always perform a
functional check of the component or system. Where
applicable, check and erase Diagnostic Trouble Codes
(DTCs) and set basic settings where applicable
according to Repair Manual and/or VAS 5051/5052.

Warning!

Some tools are supplied with a tool safety clip, which
is slid over the tool points after using the tool, in order
to protect other workers from injuries and tool points
from damage.

         „   Observe the current information in the corresponding
             Repair Manual for all repairs.


         „   Observe country-specific laws.


         „   Before working on electrical system, disconnect
             battery Ground (GND) strap.


         „   By disconnecting battery Ground (GND) strap
             (current disruption), safe work on the electrical
             system is guaranteed. It is necessary to disconnect
             battery positive wire only when removing the battery.


         „   Further information, e.g. installing and removing
             individual components, can be found in the
             appropriate Repair Manual.
Wiring Harness and Connectors, repairing                               Page 11 / 45




          „   For repairs to vehicle electrical system, soldering is
              not permitted.


          „   Only perform wiring harness and connector repairs
              to vehicle electrical system using Wiring Harness
              Repair Kit VAS1978 or Wiring Harness Repair Set
              VAS1978A .


          „   Wiring harness repairs may only be carried out using
              yellow wires.


          „   Wiring harness repairs may not be performed again
              in the wrapping of the vehicle-specific wiring harness
              and are to be marked with yellow adhesive tape.


          „   These yellow wires and every location on wiring
              harness wrapped in yellow insulating tape indicates
              a previous repair.


          „   Crimp connections must never be repaired. If
              necessary, lay a wire parallel to the faulty wire.


          „   After crimping, heat-shrink crimp connections using
              hot air gun to prevent moisture penetration.


          „   Always observe also the supplementary notes for
              repairing wiring harnesses on airbag- and seat belt
              tensioner systems, fiber optic cables, CAN-Bus
              wires, antenna wires and wire cross-sections up to
              0.35 mm 2 97-7, Notes for wiring harness
              repairs .


          „   Perform a function test after every repair. If
              necessary, check DTC memory, erase and/or bring
              systems into basic setting.


          „   If possible, do not loosen Ground (GND) straps from
              body (danger of corrosion).


Wiring harnesses, repairing

Note:

   „   Observe general notes for repairs on the vehicle
Wiring Harness and Connectors, repairing                           Page 12 / 45




       electrical system 97-7, Electrical system, general
       repair measures .


   „   Not all the wire cross-sections installed in the vehicle
       are contained in the Wiring Harness Repair Kit
       VAS1978 or Wiring Harness Repair Set
       VAS1978A . If the wire cross-section required is not
       present, use the next greater cross-section.


Caution!

          „   Note specific CAN-Bus wiring repair measures
              97-7, Repairing CAN-Bus wires .


          „   Note specific primary and secondary terminal
              and connector repair measures 97-7, Terminal
              housings, releasing and disassembling


          „   Soldering is not permitted!


          „   Do not repair welded connections in the wiring
              harness. Fabricate and connect an appropriate
              overlay harness instead.


          „   Wiring harness and connector repairs must only
              be performed using VAS 1978 Wiring Harness
              Repair Kit VAS 1978 Instruction Manual .


          „   Only the yellow repair cables and insulation tape
              supplied with VAS 1978 are to be used for
              wiring/connector repairs. The use of yellow
              repair wires and yellow insulation tape identifies
              that a repair has taken place.


          „   All shielded wiring (Eg.: knock sensors, antenna
              etc.) are Not to be repaired! Replace complete
              wiring harnesses as necessary.


Notes for wiring harness repairs

Note:

   „   Wiring harness and connector repairs to vehicle
       electrical system must only be performed using
       Wiring Harness Repair Kit VAS1978 or Wiring
       Harness Repair Set VAS1978A .
Wiring Harness and Connectors, repairing                        Page 13 / 45




   „   For repairs to vehicle electrical system, soldering is
       not permitted.


   „   Wiring harness repairs may only be performed using
       yellow wires.


   „   Wiring harness repairs may not be performed again
       in the wrapping of the vehicle-specific wiring harness
       and are to be marked with yellow adhesive tape.


   „   These yellow wires and every location on wiring
       harness wrapped in yellow insulating tape indicates
       a previous repair.


   „   Crimp connections must never be repaired. If
       necessary, lay a wire parallel to the faulty wire.


   „   After crimping, heat-shrink crimp connections using
       hot air gun to prevent moisture penetration.


   „   Shielded wires must not be repaired. Replace
       completely if damaged.


   „   Heat-resistant wires have been installed in the
       vehicle at various locations, mainly in the engine
       compartment. Heat-resistant wires can be
       recognized by their somewhat duller and softer
       insulation. Only heat-resistant wires may be used to
       repair these wires.


   „   Always observe also the supplementary notes for
       repairing wiring harnesses on airbag- and seat belt
       tensioner systems, fiber optic cables, CAN-Bus
       wires, antenna wires and wires with cross-sections
       up to 0.35 mm 2 .


Supplemental information for repairing airbag- and seat
belt tensioner wires 97-7, Repairing airbag- and seat
belt tensioner wires

Supplemental information for repairing fiber optic cables
97-7, Fiber-optic cables

Supplemental information for repairing CAN-Bus wires
Wiring Harness and Connectors, repairing                          Page 14 / 45




97-7, Repairing CAN-Bus wires

Supplemental information for replacing antenna wires
97-7, Replacing antenna wires

Supplemental information for repairing wires with a cross-
section up to 0.35 mm 2 97-7, Repairing wires with a
cross-section up to 0.35 mm 2

Repairing airbag- and seat belt tensioner wires

In addition to the general repairs on wiring harnesses,
observe the following methods and instructions for repairs
on airbag- and seat belt tensioner wires:

Warning!

           „   Airbag and seat belt tensioner can fail.


           „   Faulty repairs performed on airbag and seat belt
               tensioner system can lead to malfunction in
               passenger protection.


           „   When performing repairs on airbag and seat belt
               tensioner wiring harness, use only terminals,
               connectors and wires designated for it Parts
               Catalog (ETKA) .


Note:

   „   Only use Wiring Harness Repair Kit VAS1978 or
       Wiring Harness Repair Set VAS1978A to repair
       wires of airbag- and seat belt tensioner wiring
       harness.


   „   Pay attention to stickers designating high voltage
       components. When performing repairs, residual
       voltage must be discharged



         Repair Manual, Body Interior, Repair Group 69,
       Passenger protection

       .
Wiring Harness and Connectors, repairing                      Page 15 / 45




   „   A maximum of two repair points may be performed
       when repairing wires of airbag- and seat belt
       tensioner system. Repair points increase the
       electrical resistance in the wire and may trigger
       malfunctions in the system On Board Diagnostic
       (OBD).


   „   When repairing wiring harness of airbag- and seat
       belt tensioner system, always heat-shrink crimp
       connections to prevent corrosion.


   „   Wiring harness repairs may only be performed using
       yellow wires.


   „   Do not wrap the repair point again into the vehicle-
       specific wiring harness and mark the repair point
       quite visibly with yellow insulating tape.




   „   Repairs in the area of the airbag or seat belt
       tensioner should be performed a maximum of 30 cm
       from the next terminal housing. Together with the
       identification via yellow insulating tape, this
       procedure makes it possible to obtain a quick
       overview of previously performed repairs.
Wiring Harness and Connectors, repairing                        Page 16 / 45




   „   Wires to the deploying units (airbags) have a wire-
       twisting with a length of lay of 20 mm 5 in series
       production. This length of lay is guaranteed via the
       norm part numbers for wire pairs in series production
       and must be observed strictly for the repair lengths
       of twisted wires.




   „   During repair work, wires to deploying units (airbags)
       must have the same length. When twisting together
       wires - 1 - and - 2 - , observe strictly the length of
       lay of A=20 mm 5.


   „   While doing this, no section of the wire, e.g. in area
       of welded connectors - arrow - , may be greater
       than B = 100 mm without twisting of the wires.


Fiber-optic cables

Caution!

Fiber-optic cables on Volkswagen vehicles are not to
be repaired. In the event of malfunction, the complete
fiber-optic cable must be replaced. In this regard,
observe the following measures:

          „   Fiber optic cables are not to be kinked or
              excessively bent (bending radius must not
              exceed 25mm).


          „   Fiber-optic cable must not be routed over sharp
              edges.


          „   End pieces (lenses) must be kept free from
              contaminants, fingerprints etc.


          „   Fiber-optic cables must not be heated.
Wiring Harness and Connectors, repairing                                       Page 17 / 45




         „   A pair of fiber-optic cables must not be twisted
             together, nor should a single fiber-optic cable be
             twisted together with a copper wire conductor.


         „




Repairing CAN-Bus wires




         „   Use an unshielded two-strand wire - 1 - and - 2 -
             with a cross-section of 0.35 mm 2 or 0.5 mm 2 as a
             CAN-Bus wire.


         „   Refer to the following table for color coding of CAN-
             Bus wires:


Powertrain CAN-Bus, High                                       orange/black
Convenience CAN-Bus, High                                      orange/green
Infotainment CAN-Bus, High                                     orange/violet
CAN-Bus, Low (all)                                             orange/brown

Caution!

         „   Perform wiring harness repairs only with yellow
             wires from VAS 1978 Wiring Harness Repair Kit.
             Mark repair locations with yellow tape.


         „   Both bus wires must be the same length. When
             both wires - 1 - and - 2 - are twisted, length - A
             - = 20 mm must be maintained for the twist.


         „   No part of the bus wiring in the vicinity of heat-
Wiring Harness and Connectors, repairing                             Page 18 / 45




             shrink sleeves - arrow - , may be greater than -
             B - = 50 mm without the wires being twisted.


         „   Repairs on CAN-Bus wires can be performed with
             repair wire with matching cross section and also with
             twisted wires "green/yellow" or "white/yellow" from
             Replacement parts catalog (ETKA) .


         „   Wrap repair points with yellow adhesive tape to
             signify a repair.


Replacing antenna wires

A new repair concept has been developed for repairing
antenna wires. Instead of a complete antenna wire,
connecting wires of different lengths and various adapter
leads are now available as replacement parts.

General information:

         „   If a repair is necessary, antenna wires may not be
             repaired, but rather are to be replaced with genuine
             replacement parts, such as connecting wires and
             adapter leads.


         „   Replacement parts can be found in Parts Catalog
             (ETKA): Special catalog; electrical connections;
             original accessories; subgroup 35 as of illustration
             no. 035-20 .


         „   These genuine replacement parts are suitable for all
             antenna wires and wire cross sections, that require
             replacement.


         „   Connector housing for antenna wires can be
             obtained as a replacement part only in one color, but
             can be used for all antenna connector colors.


         „   The replacement of individual antenna connectors
             during repair work is not intended.


         „   The wires are appropriate for use on all VW models
             with equipped antenna wiring cross-sections.


         „   All adapter leads and connecting wires are suitable
Wiring Harness and Connectors, repairing                            Page 19 / 45




              for various transmission and reception signals.


          „   This repair concept can also be used for testing or
              as an aftermarket solution.




Assembly overview of antenna wire:

Example: Antenna wire from radio to antenna is faulty. For
the repair, the following wires are required:

   „   Adapter lead, for connecting to radio. Length approx.
       30 cm.
   „   Connecting wire, available in various lengths.
   „   Adapter lead, for connecting to antenna. Length
       approx. 30 cm.

Installation of a new antenna wire:

Note:

   „   Make sure that the total length of antenna wire can
       be divided into partial lengths through control
       modules for antenna selection, control modules for
       traffic monitoring or antenna amplifier. Replace only
       the respective faulty partial section.


- Disconnect electrical connections of the faulty antenna
wiring from their components.

- Determine the path of the faulty antenna wire in the
vehicle and measure the total length of antenna wire to be
replaced.
Wiring Harness and Connectors, repairing                       Page 20 / 45




The entire length of the antenna wire consists of the length
of the required adapter leads - 1 - and - 3 - as well as the
connecting wire - 2 - .

- Subtract 60 cm from the total length calculation for an
antenna wire to provide for the required length of
connecting wire - 2 - to be installed.

- Obtain the required adapter leads - 1 - and - 3 - as well
as the calculated length of connecting wire - 2 - as
genuine replacement part according to Parts Catalog.

- Cut off harness connectors of faulty antenna wire.

The rest of the faulty antenna wire remains in vehicle.

- Connect adapter leads - 1 - and - 3 - to modules in
vehicle.

- Route and secure connecting wire - 2 - parallel to the old
antenna wire.

Note:

   „   Antenna wires must not be kinked or excessively
       bent! Bending radius must never be below 50 mm.


- Connect connecting wire with adapter leads.

- Perform a function test.

Repairing wires with a cross-section up to 0.35 mm 2

When repairing wires with a cross-section up to 0.35 mm
2 , new terminals must always be crimped on using crimp
pliers for JPT-terminals VAS 1978/9A , or crimp pliers
(basic tool) VAS 1978/1-2 with mounted exchangeable
head for JPT terminal VAS 1978/9-1 . Due to the low
current strengths of these wires in the micro- to milli-
range, terminals incorrectly crimped on lead to continuity
resistances and cause malfunctions or failure of the
Wiring Harness and Connectors, repairing                       Page 21 / 45




respective system. The most frequent applications of these
terminals are:

          „   Oxygen sensor


          „   Speed (RPM) sensor


          „   Mass Air Flow (MAF) sensor


By using crimp pliers for JPT-terminals VAS 1978/9A or
crimp pliers (basic tool) VAS 1978/1-2 with mounted
exchangeable head for JPT terminal VAS 1978/9-1 ,
correct connection between crimp terminal, wire and single
wire seal is guaranteed. The tool is to be used only for the
purpose described.

Note:

   „   Terminals in a normal and a gold-plated version are
       crimped on to repair wires. Always use the same
       version of repair terminal as that installed by the
       factory.


Crimping a new terminal with single wire seal

- Insert exchangeable head for JPT terminal VAS 1978/9-
1 into crimp pliers (basic tool) VAS 1978/1-2 97-7,
Crimp pliers VAS 1978/1A (where applicable) .




- Place the single wire seal on to the repair wire - arrow -
.

Note:

   „   When doing this, the smaller diameter of single wire
       seal must face direction of terminal to be crimped
       on.
Wiring Harness and Connectors, repairing                     Page 22 / 45




- Open crimp pliers and place the repair wire end into
stripping slot of crimp pliers - arrow - .




- Close crimp pliers completely - arrows - .

- Open crimp pliers again and remove the stripped wire
end.




- Slide single wire seal in direction of stripped wire end
until it rests flush with the wire insulation.
Wiring Harness and Connectors, repairing                        Page 23 / 45




- Place new crimp terminal - arrow - into mount on crimp
pliers.




- Insert the stripped wire end with positioned single wire
seal into crimp terminal - arrow - until it makes terminal on
"wire stop" .

- Crimp the terminal, wire and single wire seal by closing
crimp pliers completely.

- Open crimp pliers again and remove the finished
crimped-on terminal.




A correctly performed crimp is distinguished by a clean
compression of wire and single wire seal in the terminal
and has an impression on the rear side which identifies
Wiring Harness and Connectors, repairing                        Page 24 / 45




that the crimp was performed by a professional using the
correct tool.

Wire break with single repair point




Repair point with single crimp connection

- Free up wire intended for repair (approx. 20 cm to both
sides of repair point).

- If required, remove wiring harness wrapping using a
folding knife.




- Cut out the damaged wire section using Wire Stripper
VAS1978/3 .

Note:

   „   If, by cutting out the damaged wire section, both
       ends of the vehicle-specific single wire are too short
       for a repair using a single crimp connection, insert a
       repair wire section of matching length with two crimp
       connections 97-7, Wire break with dual repair
       point .
Wiring Harness and Connectors, repairing                      Page 25 / 45




- Strip wire ends using 6 - 7 mm wire stripper.




- Slide crimp connection on to both stripped wire ends of
vehicle-specific single wire and crimp them using crimp
pliers.

Note:

   „   Always be sure to use the correct crimp slot for the
       crimp connection used    97-7, Crimp pliers with
       insert .


   „   Do not crimp wire insulation.


After crimping, heat-shrink crimp connections using hot air
gun to prevent moisture penetration.

- Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot
Air Gun VAS1978/14 .
Wiring Harness and Connectors, repairing                        Page 26 / 45




- Heat crimp connection using hot air gun lengthwise from
center outward until it is sealed completely and adhesive
comes out the ends.

Caution!

When heat-shrinking crimp connections, do not
damage any other wiring, plastic parts or insulating
material with the hot air gun nozzle.

Always observe operating instructions of heat gun.

Note:




   „   Make sure that crimp connections do not lie directly
       next to each other when several wires need to be
       repaired. Arrange crimp connections at a slight offset
       so that the circumference of the wiring harness does
       not become too large.


   „   In the event the repair point was taped previously,
       tape this point anew with yellow insulating tape after
       repairs.


   „   Secure the repaired wiring harness if necessary with
       a cable tie to prevent flapping noises while driving.
Wiring Harness and Connectors, repairing                       Page 27 / 45




Wire break with dual repair point




Repair point with intermediate wire section

- Free up wire intended for repair at two points (approx. 20
cm to both sides of respective repair points).

- If required, remove wiring harness wrapping using a
folding knife.




- Route yellow repair wire next to damaged wiring harness
and cut repair wire to the required length using Wire
Stripper VAS1978/3 .

- Cut damaged wire section from the vehicle-specific single
wire.
Wiring Harness and Connectors, repairing                      Page 28 / 45




- Strip wire ends using 6 - 7 mm wire stripper.

- Slide crimp connection on to vehicle-specific single wire
at one side and on to repair wire at the other side.




- Crimp the crimp connection at both wire ends using crimp
pliers.

- Repeat this procedure at the other repair wire end.

Note:

   „   Always be sure to use the correct crimp slot for the
       crimp connection used    97-7, Crimp pliers with
       insert .


   „   Do not crimp wire insulation.


After crimping, heat-shrink crimp connections using hot air
gun to prevent moisture penetration.

- Put Shrink Tip For Hot Air Gun VAS 1978/15 on to Hot
Air Gun VAS1978/14 .




- Heat crimp connection using hot air gun lengthwise from
center outward until it is sealed completely and adhesive
comes out the ends.
Wiring Harness and Connectors, repairing                        Page 29 / 45




Caution!

When heat-shrinking crimp connections, do not
damage any other wiring, plastic parts or insulating
material with the hot air gun nozzle.

Always observe operating instructions of heat gun.

Note:




   „   Make sure that crimp connections do not lie directly
       next to each other when several wires need to be
       repaired. Arrange crimp connections at a slight offset
       so that the circumference of the wiring harness does
       not become too large.


   „   In the event the repair point was previous taped, this
       point must be taped anew with yellow insulating tape
       after repairs.


   „   Secure the repaired wiring harness if necessary with
       a cable tie to prevent flapping noises while driving.


Terminal housing and harness connector repairs

Terminal housing and harness connector repairs, general
information

Note:

   „   Observe general notes for repairs on the vehicle
       electrical system 97-7, Electrical system, general
       repair measures .


   „   Allocation of crimp terminals with correct fit to
       terminal housing is performed according to the part
       number stamped in on the terminal housing. Part
       numbers of terminal housing are listed in conjunction
Wiring Harness and Connectors, repairing                         Page 30 / 45




       with the respective crimp terminals with correct fit in
       plate 198 (electrical connecting elements) in
       Replacement parts catalog (ETKA) .


   „   Damaged terminal housings must always be
       replaced.


   „   New terminal housings may be ordered via OTC
       Kassel.


Repairing terminals in terminal housing

- First, open or release if necessary the secondary lock of
the terminal housing 97-7, Terminal housings, releasing
and disassembling .




- Release terminal (primary lock) using the appropriate
release tool 97-7, Terminal housings, releasing and
disassembling .

- Pull terminal at single wire out of terminal housing.

- Take yellow repair wire with correct terminal out of wiring
harness repair kit .

- Free up repair point of vehicle-specific wiring harness
(approx. 20 cm to both sides of repair point).

- If required, remove wiring harness wrapping using a
folding knife.
You can also read
Next part ... Cancel